Liquid fuel compositions for electrochemical fuel cells

ABSTRACT

A new fuel composition useful for catalytic fuel cells is made up of at least two components. The primary fuel component is a surface active compound, such as methanol, that is a source of and acts to prevent unwanted decomposition of the auxiliary fuel. The auxiliary fuel is a hydrogen-containing inorganic compound with a high reduction potential, such as NaBH 4 , which acts as a highly reactive source of energy and serves to catalyze the catalytic oxidation of the primary fuel.

FIELD AND BACKGROUND OF THE INVENTION

[0001] The present invention relates to liquid fuel compositions for usein electrochemical fuel cells, a method of producing electricity withthe fuel compositions, and a fuel cell using the fuel compositions togenerate electricity.

[0002] A fuel cell is a device that converts the energy of a chemicalreaction into electricity. Amongst the advantages that fuel cells haveover other sources of electrical energy are high efficiency andenvironmental friendliness. Although fuel cells are increasingly gainingacceptance as electrical power sources, there are technical difficultiesthat prevent the widespread use of fuel cells in many applications.

[0003] A fuel cell produces electricity by bringing a fuel and anoxidant in contact with a catalytic anode and a catalytic cathoderespectively. When in contact with the anode, the fuel is catalyticallyoxidized on the catalyst, producing electrons and protons. The electronstravel from the anode to the cathode through an electrical circuitconnected between the electrodes. The protons pass through anelectrolyte with which both the anode and the cathode are in contact.Simultaneously the oxidant is catalytically reduced at the cathode,consuming the electrons and the protons generated at the anode.

[0004] A common type of fuel cell uses hydrogen as a fuel and oxygen asan oxidant. Specifically, hydrogen is oxidized at the anode, releasingprotons and electrons as shown in equation 1:

H₂→2H⁺+2e⁻  (1)

[0005] The protons pass through an electrolyte towards the cathode. Theelectrons travel from the anode, through an electrical load and to thecathode. At the cathode, the oxygen is reduced, combining with electronsand protons produced from the hydrogen to form water as shown inequation 2:

½ O₂+2H⁺+2e⁻→H₂O  (2)

[0006] Although fuel cells using, hydrogen as a fuel are simple, cleanand efficient the extreme flammability and the bulky high-pressure tanksnecessary for storage and transport of hydrogen mean that hydrogenpowered fuel cells are inappropriate for many applications.

[0007] In general, the storage,, handling and transport of liquids issimpler than of gases. Thus liquid fuels have been proposed for use infuel cells. Methods have been developed for converting, liquid fuelssuch as methanol into hydrogen, in situ. These methods are not simple,requiring a fuel pre-processing stage and a complex fuel regulationsystem.

[0008] Fuel cells that directly oxidize liquid fuels are the solutionfor this problem. Since the fuel is directly fed into the fuel cell,direct liquid-feed fuel cells are generally simple. Most commonly,methanol has been used as the fuel in these types of cells, as it ischeap, available from diverse sources and has a high specific energy(5025 Wh/kg).

[0009] In direct-feed methanol fuel cells, the methanol is catalyticallyoxidized at the anode producing electrons, protons and carbon monoxide,equation 3:

CH₃OH→CO+4H⁺+4e⁻  (3)

[0010] Carbon monoxide tightly binds to the catalytic sites on theanode. The number of available sites for further oxidation is reduced,reducing power output. One solution is to use anode catalysts which areless susceptible to CO adsorption, such as platinum/ruthenium alloys.

[0011] Another solution has been to introduce the fuel into the cell asan “anolyte”, a mixture of methanol with an aqueous liquid electrolyte.The methanol reacts with water at the anode to produce carbon dioxideand hydrogen ions, equation 4:

CH₃OH+H₂O→6H⁺CO₂6e⁻  (4)

[0012] In fuel cells that use anolytes, the composition of the anolyteis an important design consideration. The anolyte must have both a highelectrical conductivity and high ionic mobility at the optimal fuelconcentration. Acidic solutions are most commonly used. Unfortunately,acidic anolytes are most efficient at relatively high temperatures,temperatures at which the acidity can to passivate or destroy the anode.Anolytes with a pH close to 7 are anode-friendly, but have an electricalconductivity that is too low for efficient electricity generation.Consequently, most prior art direct methanol fuel cells use solidpolymer electrolyte (SPE) membranes.

[0013] In a cell using SPE membrane, the cathode is exposed to oxygen inthe air and is separated from the anode by a proton exchange membranethat acts both as an electrolyte and as a physical barrier preventingleakage from the anode compartment wherein the liquid anolyte iscontained. One membrane commonly used as a fuel cell solid electrolyteis a perfluorocarbon material sold by E. I. DuPont de Nemours ofWilmington Del. under the trademark “Nafion.” Fuel cells using SPEmembranes have a higher power density and longer operating lifetimescompared to other anolyte based cells. One disadvantage SPE membranefuel cells have arises from the tendency of methanol to diffuse throughthe membrane. As a result, much methanol is not utilized for generationof electricity but is lost through evaporation. In addition, if themethanol comes in contact with the cathode, a “short-circuit” occurs asthe methanol is oxidized directly on the cathode, generating heatinstead of electricity. Further, depending upon the nature of thecathode catalyst and of the oxidant, catalyst poisoning or cathodesintering often occurs.

[0014] The diffusion problem is overcome by using anolytes with a low(up to 5%) methanol content. The low methanol content limits theefficiency of the fuel cell as the methanol diffusion rate limitselectrical output. Efficiency is also limited when measured in terms ofelectrical output as a function of volume of fuel consumed and raisesissues of fuel transportation, dead weight and waste disposal.

[0015] Lastly, despite a high specific energy, methanol is ratherunreactive. As a result, the performance of direct-feed liquid methanolfuel cells is limited to about 5 mWcm⁻².

[0016] An alternative fuel to consider is one composed ofhydrogen-containing inorganic compounds with a high reduction potentialsuch as metal hydrides and hydrazine and its derivatives. Such compoundshave a high specific energy and are highly reactive.

[0017] One such compound is NaBH₄. In water. NaBH₄ dissociates to giveBH₄ ⁻. In a neutral solution BH₄ ⁻is oxidized at the anode according toequation 5:

BH₄ ⁻+2 H₂O→BO₂ ⁻+8H⁻+8e⁻  (5)

[0018] The greatest drawbacks of hydrogen-containing inorganic compoundsas fuel is the spontaneous decomposition of these compounds in acidicand neutral solutions, equation 6:

BH₄ ⁻+2 H₂O→BO₂ ⁻+4H₂  (6)

[0019] In a basic solution BH₄ ⁻is oxidized at the anode according toequation 7:

BH₄ ⁻+8 OH⁻→BO₂ ⁻6 H₂O+8e⁻  (7)

[0020] Although stable in basic solutions, BH₄ ⁻decomposes on contactwith a catalyst, such as found on the anode of a fuel cell, even whenthe circuit is broken.

[0021] There is a need for a liquid fuel composition for fuel cells thatcan produce high power and is stable in contact with the catalytic anodewhen the electrochemical circuit is broken.

SUMMARY OF THE INVENTION

[0022] The above and other objectives are achieved by the innovativefuel composition provided by the invention. The fuel composition is madeup of a combination of a primary fuel and an auxiliary fuel. The primaryfuel is a mixture of one or more compounds, of which at least one is asurface active compound, most preferably an alcohol such as methanol.The auxiliary fuel is a mixture of one or more hydrogen-containinginorganic compounds with a high reduction potential such as metalhydrides, hydrazine and hydrazine derivatives.

[0023] The invention further provides the fuel composition as an“anolyte” where the electrolyte component of the fuel composition has apH above 7, most preferably an aqueous solution of an alkali metalhydroxide such as KOH.

[0024] The invention further provides a fuel cell for the generation ofelectrical power, made up of an anode, a cathode, and a fuel compositionmade up of at least one surface active compound and at least onehydrogen-containing inorganic compound with a high reduction potential.

[0025] Still further, the invention provides a method of producingelectricity through the steps of providing a fuel cell with an anode, acathode and a fuel composition made up of at least active compound andat least one hydrogen-containing inorganic compound with a highreduction potential, bringing the fuel composition in contact with theanode, oxidizing the fuel composition, and obtaining electricity fromthe fuel cell.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The invention is herein described, by way of example only, withreference to the accompanying drawings, where:

[0027]FIG. 1 is an embodiment of the fuel cell of the invention wherethe fuel composition is supplied as an anolyte;

[0028]FIG. 2 is an embodiment of the fuel cell of the inventionincorporating a solid electrolyte membrane;

[0029]FIG. 3a is a graph showing experimental results of current as afunction of time generated by a cell as in FIG. 1 using a fuelcomposition of 20% methanol as an anolyte: and

[0030]FIG. 3b is a graph showing experimental results of current as afunction of time generated by a cell as in FIG. 1 using a fuelcomposition of 20% methanol and 5% NaBH₄ as an anolyte.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The fuel composition provided by the invention consists of atleast two components: a primary fuel and an auxiliary fuel. The primaryfuel is composed of a mixture of one or more compounds, of which atleast one is a surface active compound, most preferably an alcohol suchas methanol. The auxiliary fuel is a mixture of one or morehydrogen-containing inorganic compounds with a high reduction potentialsuch as metal hydrides, hydrazine and hydrazine derivatives.

[0032] The purpose of the primary fuel is two-fold, to be a source ofelectrical energy by undergoing oxidation at the anode and to preventundesired decomposition of the auxiliary fuel. For the latter function,the primary fuel must have some level of surface activity. As usedherein, surface activity is defined as the property of substantiallypreventing contact between the auxiliary fuel and the catalytic sites ofthe anode. While not wishing to be held to any theory, it is believedthat the primary fuel of the invention probably prevents unwantedspontaneous oxidation of the auxiliary fuel when the electrical circuitis open by two mechanisms. The first mechanism is that effectiveadsorption of molecules of the primary fuel to the anode catalytic sitessterically obstructs access of the auxiliary fuel to the sites,preventing decomposition. The second mechanism is that the molecules ofthe primary fuel effectively solvate the auxiliary fuel species. As longas a shell of primary fuel molecules surrounds the auxiliary fuelspecies, it cannot make contact with the anode catalytic sites and doesnot decompose.

[0033] Once the electrical circuit is closed, oxidation of the adsorbedprimary fuel molecules commences. The anode catalytic sites become freefor access of other species. At least one primary fuel moleculesolvating the auxiliary fuel molecule is likely be oxidized before theauxiliary fuel species can approach the catalytic sites of the anode tobe oxidized.

[0034] Many classes of compounds can be countenanced when selecting theprimary fuel for the purpose of being a source of energy, mostpreferably alcohols. Methanol is a prime candidate due to itsavailability and high specific energy. For the purpose of adsorptiononto the anode catalytic sites, bulkier alcohols or other surface-activecompounds can be considered as primary fuels. For instance, isopropanolor glycerol are likely more suitable for this purpose than methanol. Forthe purpose of auxiliary fuel salvation, the ideal primary fuel isdependent on the identity of the auxiliary fuel.

[0035] The auxiliary fuel component of the invention is selected fromamongst hydrogen-containing inorganic compounds with a high reductionpotential. Metal hydrides such as LiAlH₄, NaBH₄, LiBH₄, (CH₃)₂NHBH₃,NaAlH₄, B₂H₆, NaCNBH₃CaH₂, LIH, NaH, KH or sodium his (2-methoxyethoxo)dihydridaluminate are suitable as the auxiliary fuel. Hydrazine orhydrazine derivatives are also suitable. As described above,hydrogen-containing inorganic compounds with a high reduction potentialare good fuels for fuel cells but are plagued by over-reactivity. Whenthese compounds are found in an appropriate solution and prevented fromcontact with the anode catalytic centers according to the invention,they are stable.

[0036] Additionally, the presence of the auxiliary fuel increases therate of catalytic oxidation of the primary fuel. While not wishing to beheld to any theory, it is believed that primary fuel oxidation productssuch as CO and CO₂ are effectively removed from the anode catalyticsites by the oxidation of the auxiliary fuel.

[0037] Thus the combination of the primary fuel and the auxiliary fuelof the invention has a synergistic effect on catalytic oxidation in afuel cell using a fuel composition of the invention.

[0038] It is clear to one skilled in the art that there are a number offactors that influence the exact composition of a fuel composition ofthe invention. Instead of choosing one compound as the primary fuel, amixture of compounds is often preferred. Similarly, a mixture ofcompounds is often preferable to form the auxiliary fuel.

[0039] Factors to be considered when formulating a fuel compositionaccording to the invention are solubility, stability, safety and factorsthat arise from the desired qualities of the generated electricalcurrent. Conceivably, additives that are neither primary nor auxiliaryfuel can be added to the fuel composition. Additives that stabilize thefuel composition, directly modify the qualities of the generatedelectricity modify the solubility of the components so as to indirectlymodify the qualities of the electricity generated or in some other wayimprove the performance of the fuel composition used in a fuel cell, canbe used. Engineering issues also dictate the exact composition of thefuel composition: for example, a fuel composition composed of methanoland NaBH₄ could contain sodium methoxide as a stabilizing agent.

[0040] In one embodiment of the invention, the fuel composition asdescribed above is supplied as an anolyte, that is, an electrolyticliquid is added in addition to the primary and auxiliary fuel. Thepreferred electrolytic liquid is a basic aqueous solution, preferably ofan alkali metal hydroxide, such as KOH (See, for example, Hirchenhofer,J. H., Staufer. D. B. and Engleman, R. R. Fuel Cells—A Handbook(revision 3) DOE/METC-94-1006. January 1994). The alkali metal hydroxideconcentration in the anolyte is typically between 2 and 12 M. In theart, 6 M KOH has been shown to be ideal for fuel cell operation atambient temperatures (see, for example, Appelby, A. J. and Foulkes, F.R., Fuel Cell Handbook, Krieger Publishing, Malabar, Fla. 1993, Chapters8, 10, 11, 12. 13, 16). The addition of the electrolytic liquid has apositive effect on ion mobility within the anolyte fuel and helps ensurethe stability of the auxiliary fuel component of the fuel. Whenconsidering the exact composition of the fuel composition of theinvention when supplied as an anolyte, factors such as stability andsolubility are taken into account.

[0041] The principles and operation of a fuel cell and generation ofelectricity according to the invention may be better understood withreference to the figures and accompanying description.

[0042] In FIG. 1, a simplified fuel cell 10 typical of the invention isillustrated. Oxidant 12 is oxygen from air and has free contact withcathode 14. Cathode 14 is made using screen-printing methods of 20%platinum on activated carbon on waterproof paper. Cathode 14 is incontact with and acts as a barrier against leakage of electrolyte 16contained within electrolyte chamber 18. Electrolyte 16 is a 6 M KOHaqueous solution. Electrolyte chamber 18 is separated from fuel chamber22 by anode 20. Anode 20 is made using screen-printing methods of 20%platinum and 10% ruthenium on activated carbon on hydrophilic carbonpaper. Fuel composition 24 contained within fuel chamber 22 is suppliedas an anolyte composed of a combination of a primary fuel, which issurface active compound such as methanol, an auxiliary fuel, which is ahydrogen-containing inorganic compound with a high reduction potentialsuch as NaBH₄, and an electrolyte such as a 6 M KOH solution. Electricalcircuit 26, made up of load 28 and switch 30, electrically connectsanode 20 to the cathode 14.

[0043] When switch 30 is open, methanol in fuel chamber 22 is adsorbedonto the catalytic sites on anode 20, preventing contact between the BH₄⁻species in fuel composition 24 and the catalytic sites. The methanolalso solvates the BH₄ ⁻species, further isolating the BH₄ ⁻species fromthe catalytic sites. When switch 30 is closed, the methane molecules atthe catalytic sites are oxidized, clearing the sites for contact withand oxidation of more fuel including BH₄ ⁻species. Electrons formed bycatalytic oxidation of fuel composition 24 are transported throughelectrical circuit 26 to cathode 14. Simultaneously, protons formed bycatalytic oxidation are transported from anode 14, through electrolyte16 and to cathode 14. At cathode 14, oxidant 12 is reduced by the actionof cathode 14 and the electrons coming through circuit 26, and combineswith the protons to form water.

[0044] In an additional embodiment, appearing in FIG. 2, the fuelcomposition is used without a liquid electrolyte in fuel cell 40.Oxidant 42 is oxygen from the air and has free contact with membraneelectrode assembly 44. Membrane electrode assembly 44 has a layeredsandwich structure with two sides. One side is a catalytic cathode layer46 connected to a solid polymer electrolyte (proton exchange membrane)48 which transports protons and acts as a barrier preventing passage ofother molecular species. Electrolyte layer 48 is connected to an anodelayer 50. Anode layer 50 is in contact with fuel composition 52contained within fuel chamber 54. Fuel composition 52 is composed of acombination of a primary fuel such as methanol, and an auxiliary fuelsuch as NaBH₄. Electrical circuit 56, made up of load 58 and switch 60,electrically connects anode layer 50 to cathode layer 46.

[0045] When switch 60 is open, methanol from fuel composition 52 isadsorbed onto the catalytic sites on anode layer 50, preventing contactbetween the BH₄ ⁻species and the catalytic sites. Similarly, themethanol solvates the BH₄ ⁻species, further isolating the BH₄ ⁻species.When switch 60 is closed, the methanol molecules at the catalytic sitesare oxidized, clearing the catalytic sites for contact with andoxidation of the all fuel components. Electrons formed by catalyticoxidation are transported through electrical circuit 56 to cathode layer46. Protons formed by the catalytic oxidation are transported throughanode layer 50, through electrolyte layer 48 and to cathode layer 46. Atcathode layer 46, oxidant 42 is reduced by the action of catalyticcathode layer 46 and the electrons coming through circuit 56, andcombines with the protons to form water.

[0046] Many other embodiments of the invention can be countenanced.Whereas the embodiments above are described using oxygen from air as anoxidant, with the necessary modifications a liquid oxidant can be used,for example, an organic fluid with a high oxygen concentration (see U.S.Pat. No. 5,185,218) or a hydrogen peroxide solution.

[0047] Similarly the choice of catalyst for anode and cathodeconstruction is not limited to those made of precious metals as in theembodiments described above. (See, for example, Fuel Cell Systems, (eds.Blomen. L. J. M. J and Mugerwa, M. N.), Plenum Press, New York, 1993,Chapter 2: pp. 42-52. 63-69, Chapter 3: pp. 88-97, p. 110. Chapters 7,8, 11)

EXAMPLE 1

[0048] A fuel cell, similar to that described in FIG. 1 and described inthe specification was constructed, wherein both anode and cathode had anarea of 4 cm². 6 M KOH was put in the electrolyte chamber and a mixtureof 20% methanol and 80% 3 M KOH solution was put in the fuel chamber.Current at U=0.5 V was measured as a function of time. A current of 5±1mA was measured over 60 minutes. The graph of the measured current as afunction is time is presented in FIG. 3a.

EXAMPLE 2

[0049] The current at U=0.5 V was measured as a function of time in afuel cell as in Example 1, wherein to the methanol/KOH solution 5 weightpercent NaBH₄ was added. A current of 240±5 mA was measured over 90minutes. The graph of the measured current as a function is time ispresented in FIG. 3a.

[0050] While the invention has been described with respect to a limitednumber of embodiments, it will be appreciated that many variations,modifications and other applications of the invention may be made.

What is claimed is:
 1. A fuel composition, comprising a) a primary fuel including at least one surface-active compound; and b) an auxiliary fuel including at least one hydrogen-containing inorganic compound with a high reduction potential.
 2. The fuel composition of claim 1 wherein said surface-active compound is a compound with an —OH functional group.
 3. The fuel composition of claim 2 wherein said surface-active compound includes at least one compound from the group consisting of CH₄O, C₂H₆O, C₃H₈O, C₄H₁₀O, C₅H₁₂O, C₆H₁₄O, ethylene glycol and glycerine.
 4. The fuel composition of claim 1 further comprising at least one additional compound.
 5. The fuel composition of claim 1 wherein said auxiliary fuel includes at least one compound from the group consisting of metal hydrides, hydrazine, and hydrazine derivatives.
 6. The fuel composition of claim 5 wherein said auxiliary fuel includes at least one compound from the group consisting of LiAlH₄, NaBH₄, LiBH₄, (CH₃)₂NHBH₃, NaAlH₄, B₂H₆, NaCNBH₃, CaH₂, LiH, NaH, KH and sodium bis (2-methoxyethoxo) dihydridaluminate.
 7. The fuel composition of claim 1 further comprising an electrolyte with a pH above about
 7. 8. The fuel composition of claim 7 wherein said electrolyte is substantially an aqueous solution of an alkali metal hydroxide.
 9. The fuel composition of claim 8 wherein said alkali metal hydroxide is KOH.
 10. The fuel composition of claim 9 wherein said electrolyte has a concentration of KOH between about 3 M and about 12 M.
 11. The fuel composition of claim 10 wherein said concentration is substantially 6 M.
 12. The fuel composition of claim 7 comprising between 2 weight percent and 60 weight percent of said primary fuel and between 1 weight percent and saturation of said auxiliary fuel.
 13. A fuel cell for the generation of electrical power, comprising a) an anode; b) a cathode; and c) a fuel composition including at least one surface active compound and at least one hydrogen-containing inorganic compound with a high reduction potential.
 14. The fuel cell of claim 13 wherein at least one of said surface-active compounds is an alcohol, and wherein at least one of said hydrogen-containing inorganic compound is selected from the group consisting of metal hydrides, hydrazine and hydrazine derivatives.
 15. The fuel cell of claim 14 wherein said hydrogen-containing inorganic compound is selected from the group consisting of LiAlH₄, NaB₄, LiBH₄, (CH₃)₂NHBH₃, NaAlH₄, B₂H₆, NaCNBH₃, CaH₂, LiH, NaH, KH and sodium bis (2-methoxyethoxo) dihydridaluminate.
 16. A method for generating electricity comprising the steps of: a) providing a fuel cell that includes a cathode and an anode; b) providing a fuel composition including at least one hydrogen-containing inorganic compound with a high reduction potential and at least one surface active compound; c) providing a circuit connecting said cathode and said anode; and d) contacting said fuel composition with said anode to oxidize said fuel composition.
 17. The method of to claim 16 wherein at least one of said surface-active compounds is an alcohol, and wherein at least one of said hydrogen-containing inorganic compound is selected from the group consisting of metal hydrides, hydrazine and hydrazine derivatives.
 18. The method of claim 17 wherein said hydrogen-containing inorganic compound is selected from the group consisting of LiAlH₄, NaBH₄, LiBH₄, (CH₃)₂NHBH₃, NaAlH₄, B₂H₆, NaCNBH₃, CaH₂, LiH, NaH, KH and sodium bis (2methoxyethoxo) dihydridaluminate. 